The visit to Makino was indeed an enriching one, and one which we had many takeaways. The company takes pride in the precision of its products, and is constantly at the frontier of precision engineering through R&D and continuous training for its employees. Moreover, many things we learnt from the visit were extremely interesting, especially since it can be linked to our academic curriculum in school.
Physics
Precision Engineering -One of the major takeaways from the visit was that of precision, and the tolerance of errors for precise measurements is only 5 microns, or 0.005mm. Besides the difficulty in achieving that minute precision, many other internal and external factors have to be considered, and adjustments have to be made accordingly for each machine to live up to Makino’s reputation. External factors such as dust have to be avoided at all costs, hence the production of some parts such as the spindle in a clean room.We thus learnt much about the processes and tools used in ensuring and verifying quality, such as using intricate tools to measure if 2 planes are parallel, and running trial tests to ascertain the durability and precision of movement of machinery.
Thermal Expansion of metal
The internal factors which affect metal expansion include the temperature of the machine, which is kept constant via a liquid cooling system, since high temperatures which are caused by either friction or the conversion of electrical energy to heat energy during work may result in expansion of material. Through a tour of the Makino training facility we witnessed for ourselves how metal expands when exposed to as little heat as that which emanates from our hands. We saw this phenomenon from clutching a metal bar and watching its width expand, as shown by a micrometer screw gauge reading.
Formula for thermal expansion of materials: Where alpha is the linear coefficient of thermal expansion, we have learnt, and through research verified that the change in length of the material is directly proportional to the change in temperature. According to our tour guide, a degree change in temperature would result in a change in length of 50 microns for a metal 1m long.
Lasers
Lasers are used to determine how much the machine part has moved. Laser is beamed towards the machine part. Lasers travel in a straight line and are an accurate tool for testing. When the machine part is moved into the path of the laser, the laser beam is reflected off the metallic part. The reflected beam then travels in the opposite direction, and is then detected by a computer. If the laser beam is reflected off at the wrong time, this indicates that the machine requires calibration and optimization. This allows the operators to know if the machine is in good condition.
Chemistry
Rusting
-During our trip to Makino we witnessed how the company ensured durability of products by ensuring their machines do not rust. This was put in to place by coating their steel and iron machinery with a thick blue coating except at critical areas where machine parts were attached. This is in line with what we have learnt in chemistry class, whereby by coating metals with an impermeable layer blocking out water vapour in air, the object will not rust.
The internal factors include the temperature of the machine, which is kept constant via a liquid cooling system, since high temperatures which are caused by either friction or the conversion of electrical energy to heat energy during work may result in expansion of material. External factors such as dust have to be avoided at all costs, hence the production of some parts such as the spindle in a clean room.
Computer programming
Computer programming is also used to calibrate and move the machine parts. Parts of the testing are automated and do not require manual labour.
During the laser testing, computers were also used to move the machine parts vertically. The data was also logged by the computer, and the computer makes the necessary adjustments, like moving 1 axis by a few microns, to achieve the desired precision.
The computer in the machine is also programmed to regulate and constantly monitor the temperature of the machine. When the machine is operating, temperature sensors in the machine will allow the computer to determine its temperature. If the temperature is too high, the computer will activate the cooling system to lower the machine’s temperature. The temperature can be adjusted to allow the machine to operate in different working conditions.
The machine is also programmed to have the capability to replace its own parts. For instance, when milling a wooden block, a larger part is required. With a few clicks, the machine is able to remove its existing parts and replace them with a different set of parts. This ensures that the machine is operating at its optimum condition, through extensive evaluation and optimization.
Research and development
Another interesting concept we learnt from the visit is process of developing a new machine. The idea is created in the research and development part of the company, and after the researchers and engineers have come up with a feasible plan, the prototype will be created. The prototype will have to undergo several tests to ensure that it is able to run as expected in a normal working condition. After it is proven that the prototype works, the product will be marketed to businesses. The whole process, from coming up with the idea to the prototype, takes around 12 months.
Physics
Precision Engineering-One of the major takeaways from the visit was that of precision, and the tolerance of errors for precise measurements is only 5 microns, or 0.005mm. Besides the difficulty in achieving that minute precision, many other internal and external factors have to be considered, and adjustments have to be made accordingly for each machine to live up to Makino’s reputation. External factors such as dust have to be avoided at all costs, hence the production of some parts such as the spindle in a clean room.We thus learnt much about the processes and tools used in ensuring and verifying quality, such as using intricate tools to measure if 2 planes are parallel, and running trial tests to ascertain the durability and precision of movement of machinery.
Thermal Expansion of metal
The internal factors which affect metal expansion include the temperature of the machine, which is kept constant via a liquid cooling system, since high temperatures which are caused by either friction or the conversion of electrical energy to heat energy during work may result in expansion of material. Through a tour of the Makino training facility we witnessed for ourselves how metal expands when exposed to as little heat as that which emanates from our hands. We saw this phenomenon from clutching a metal bar and watching its width expand, as shown by a micrometer screw gauge reading.
Formula for thermal expansion of materials: Where alpha is the linear coefficient of thermal expansion, we have learnt, and through research verified that the change in length of the material is directly proportional to the change in temperature. According to our tour guide, a degree change in temperature would result in a change in length of 50 microns for a metal 1m long.
Lasers
Lasers are used to determine how much the machine part has moved. Laser is beamed towards the machine part. Lasers travel in a straight line and are an accurate tool for testing. When the machine part is moved into the path of the laser, the laser beam is reflected off the metallic part. The reflected beam then travels in the opposite direction, and is then detected by a computer. If the laser beam is reflected off at the wrong time, this indicates that the machine requires calibration and optimization. This allows the operators to know if the machine is in good condition.
Chemistry
Rusting-During our trip to Makino we witnessed how the company ensured durability of products by ensuring their machines do not rust. This was put in to place by coating their steel and iron machinery with a thick blue coating except at critical areas where machine parts were attached. This is in line with what we have learnt in chemistry class, whereby by coating metals with an impermeable layer blocking out water vapour in air, the object will not rust.
The internal factors include the temperature of the machine, which is kept constant via a liquid cooling system, since high temperatures which are caused by either friction or the conversion of electrical energy to heat energy during work may result in expansion of material. External factors such as dust have to be avoided at all costs, hence the production of some parts such as the spindle in a clean room.
Computer programming
Computer programming is also used to calibrate and move the machine parts. Parts of the testing are automated and do not require manual labour.
During the laser testing, computers were also used to move the machine parts vertically. The data was also logged by the computer, and the computer makes the necessary adjustments, like moving 1 axis by a few microns, to achieve the desired precision.
The computer in the machine is also programmed to regulate and constantly monitor the temperature of the machine. When the machine is operating, temperature sensors in the machine will allow the computer to determine its temperature. If the temperature is too high, the computer will activate the cooling system to lower the machine’s temperature. The temperature can be adjusted to allow the machine to operate in different working conditions.
The machine is also programmed to have the capability to replace its own parts. For instance, when milling a wooden block, a larger part is required. With a few clicks, the machine is able to remove its existing parts and replace them with a different set of parts. This ensures that the machine is operating at its optimum condition, through extensive evaluation and optimization.
Research and development
Another interesting concept we learnt from the visit is process of developing a new machine. The idea is created in the research and development part of the company, and after the researchers and engineers have come up with a feasible plan, the prototype will be created. The prototype will have to undergo several tests to ensure that it is able to run as expected in a normal working condition. After it is proven that the prototype works, the product will be marketed to businesses. The whole process, from coming up with the idea to the prototype, takes around 12 months.